New product and a method for its manufacture

ABSTRACT

The present invention provides a tobacco product, which gives a high yield of taste and nicotine without chewing and has a pleasant appearance, comprising a multi-layer (laminate) structure wherein the product comprises at least one load layer and a construction layer. Also provided is a method for manufacturing said tobacco product comprising the following step: pressing at least one load layer with a construction layer in a press apparatus.

[0001] This invention concerns the technical field of tobacco-containing products, especially tobacco-containing products, which give a high yield of taste and nicotine without chewing and, which gives a pleasant appearance. In particular, a laminated tobacco product and a method for its manufacture are disclosed.

BACKGROUND

[0002] There are gum-containing tobacco products previously known. In U.S. Pat. No. 4,802,498, U.S. Pat. No. 5,092,352 and U.S. Pat. No. 5,845,647 there are chewable gum-containing tobacco products disclosed. In U.S. Pat. No. 4,545,392 there is also a gum-containing tobacco product disclosed which is chewable.

[0003] The appearance of products presently on the market can still however be improved. Tobacco-containing products for use in the mouth (oral use) presently on the market also often need to be chewed in order to give a high yield of taste and nicotine.

[0004] Accordingly there is a need for tobacco products, which give a high yield of taste and nicotine without chewing, and offer a good appearance.

SUMMARY OF THE INVENTION

[0005] The present invention solves one or more of the above problems by providing according to a first aspect of the invention a tobacco product, which gives a high yield of taste and nicotine without chewing and has a pleasant appearance, comprising a multi-layer (laminate) structure wherein the product comprises at least one load layer and a construction layer. Also provided, according to a second aspect of the present invention, is a method for manufacturing a tobacco product according to the first aspect of the invention, comprising the following step: pressing at least one load layer with a construction layer in a press apparatus.

DETAILED DESCRIPTION OF THE INVENTION

[0006] It is intended throughout the present description that the expression “tobacco product” or “tobacco composition” (used interchangeably in the present description) embrace any composition or product comprising tobacco in any form.

[0007] It is intended throughout the present description that the expression “load layer” embrace any layer comprising an essential amount of tobacco raw material.

[0008] It is intended throughout the present description that the expression “construction layer” embrace a backbone layer and a cosmetic layer. The backbone layer may comprise an essential amount of tobacco raw material or it may lack tobacco.

[0009] It is intended throughout the present description that the expression “tobacco raw material” or “tobacco” (used interchangeably in the present description) embrace any tobacco type available or mixtures thereof. Examples of tobacco types are: Rustika, Va., Burley, Oriental and Kentucky. Preferably the tobacco is tobacco in powder form. The tobacco powder is preferably obtained by breaking up, drying and feeding raw tobacco into a grinder. The ground (or cut) tobacco is then sieved into three particle size fractions: coarse, medium and fine. Pre-set quantities of the three fractions may be fed into a mixer silo where the tobacco flour is mixed. After blending, the tobacco flour is fed into a storage silo, from which flour may automatically be taken for processing into a tobacco product. Each type of tobacco flour is preferably kept in a separate silo. The tobacco may also be flue cured, air cured, sun cured or fire cured.

[0010] It is intended throughout the present description that the expression “load layer composition” embraces any composition suitable for use in the load layers of the multi-layer tobacco product according to the first aspect of the present invention. Preferably said load layer composition comprises tobacco powder (flour), a filler (texturizer), a plasticizer, a solvent and a gum base. The load layer composition may also comprise sweeteners, pH adjusting agents, colours and flavours or combinations thereof, and if the amount of additives is large it may be necessary to reduce the amount of filler or tobacco powder to keep the plastic properties.

[0011] It is intended throughout the present description that the expression “construction layer composition” embraces any composition suitable for use in the backbone layer or in the cosmetic layer of the multi-layer tobacco product according to the first aspect of the present invention. Preferably said construction layer composition comprises a gum base, and optionally tobacco powder, a plasticizer and a solvent. The construction layer composition may also comprise sweeteners, pH adjusting agents, colours and flavours or combinations thereof, and if the amount of additives is large it may be necessary to reduce the amount of tobacco powder to keep the plastic properties.

[0012] The backbone layer may comprise a construction layer composition or a solid fiber material such as woven.

[0013] The cosmetic layer may comprise a construction layer composition or a plastic or paper material or a combination thereof.

[0014] The filler (texturizer) may be selected from the group comprising the following compounds: titanium dioxide, zinc oxide, calcium carbonate, alumina, alumiminium hydroxide, alumiminium oxide and magnesium silicate or combinations thereof. Preferably the filler is titanium dioxide (TiO₂).

[0015] The plasticizer may be hydrophilic or hydrophobic (i.e. lipophilic). Examples of hydrophilic plasticizers are glycerol, propylene glycol and polyethylene glycol and combinations thereof. Preferably glycerol is used as plasticizer. Examples of hydrophobic plasticizers (softeners) are lecithin, cephalin, Tweens, Spans, glyceryl monostearate and beeswax or combinations thereof. Fats may also be used as hydrophobic plasticizers.

[0016] The solvent is preferably water or ethanol, or a combination thereof. Most preferred water is used.

[0017] The gum base is preferably a chewing gum base. An example of a chewing gum base is Smily 2 toco Pellets obtainable from Gum Base Company S. p. A., Italy.

[0018] According to a preferred embodiment of the first aspect of the present invention the load layers may be internally multi-layered. The load layer composition is generally present in the form of a dough when its components have been mixed and then the composition is processed in a press, preferably in a roller press such as a pasta machine. Then the load layer may be rolled, sprinkled with cornstarch or similar and folded. Then again the load layer is pressed again. This may be repeated for at least 30 times, to a thinner and thinner plate. The end thickness is preferably about 1 mm.

[0019] According to a preferred embodiment of the first aspect of the present invention the composition comprises at least two load layers with an intermediate backbone layer.

[0020] According to a preferred embodiment of the first aspect of the present invention the composition comprises at least two cosmetic layers with an intermediate load layer.

[0021] According to a preferred embodiment of the first aspect of the present invention the backbone layer may be internally multi-layered or in the form of a mono-layer. The construction layer composition may be processed in a press, preferably in a roller press such as a pasta machine. Preferably the backbone layer has a thickness which is less than 0,5 mm.

[0022] According to a preferred embodiment of the first aspect of the present invention the load layers comprise a load layer composition.

[0023] According to a preferred embodiment of the first aspect of the present invention the load layer composition comprises tobacco powder, filler, a plasticizer, a solvent and a gum base.

[0024] According to a preferred embodiment of the first aspect of the present invention the load layer composition comprises tobacco powder, titanium dioxide, glycerol, water and chewing gum base.

[0025] According to a preferred embodiment of the first aspect of the present invention the backbone layer comprise a construction layer composition.

[0026] According to a preferred embodiment of the first aspect of the present invention the construction layer composition comprises a gum base, and optionally tobacco powder, a plasticizer and a solvent.

[0027] According to a preferred embodiment of the first aspect of the present invention the construction layer composition comprises a chewing gum base, and optionally tobacco powder, glycerol and water.

[0028] According to a preferred embodiment of the first aspect of the present invention the tobacco product comprises additionally a lipophilic softener.

[0029] According to a preferred embodiment of the first aspect of the present invention the tobacco product is contained in cloth, wherein said cloth preferably comprises heat sealable nonwoven.

[0030] According to a preferred embodiment of the second aspect of the present invention the method for manufacturing a tobacco composition comprises the following step: pressing at least two load layers, comprising a load layer composition, with an intermediate construction layer in the form of a backbone layer, comprising a construction layer composition, in a press apparatus.

[0031] According to a preferred embodiment of the second aspect of the present invention the method for manufacturing a tobacco composition comprises the following step: pressing at least two construction layers in the form of at least two cosmetic layers, each comprising a construction layer composition, with an intermediate load layer, comprising a load layer composition, in a press apparatus.

[0032] According to a preferred embodiment of the second aspect of the present invention the load layer composition has been manufactured using a method comprising the following steps:

[0033] a) mixing tobacco powder, filler, plasticizer, and the solvent,

[0034] b) heating the mixture; and

[0035] c) adding a gum base.

[0036] According to a preferred embodiment of the second aspect of the present invention the construction layer composition has been manufactured using a method comprising the following steps:

[0037] a) heating gum base to a mixture with a suitable consistency; and optionally

[0038] b) adding the gum base to a mixed solution comprising tobacco powder, a plasticizer and a solvent.

[0039] According to a preferred embodiment of the second aspect of the present invention, one or more sweeteners, pH adjusting agents, colours or flavours are added.

[0040] According to a preferred embodiment of the second aspect of the present invention the load layers are pressed repeatedly after folding, preferably more than 30 times, before the backbone layer is added to the load layers to form the multi-layered tobacco product.

[0041] According to a preferred embodiment of the second aspect of the present invention a lubricant is distributed on the load layers before each folding, preferably the load layers are sprinkled with cornstarch before each folding. The lubricant may be potato fluor, talc or cornstarch, preferably cornstarch.

[0042] According to a preferred embodiment of the second aspect of the present invention the tobacco product is coated with a coating layer or is patterned. A method of achieving a patterning effect on the tobacco product surface and therefore a further preferred embodiment of the invention, comprises continuously printing the tobacco product with a coating substance, leaving gaps on the tobacco product that may correspond to marks, logotypes, texts or anagrams, thereby for printing of the tobacco product. A coloring agent may further penetrate through the outer layer of the tobacco product at such open points and not on the remaining surface that would be protected by the coating substance. Printing may thus be based upon applying the coating substance as a printed background, leaving the foreground or printed characters without this coating substance, and hence when the tobacco product with the layers inside undergoes coloring operations, it will only be penetrated through areas without the coating substance, leaving the surface of such tobacco product marked by the areas without coating substance.

[0043] According to a preferred embodiment of the second aspect of the present invention the tobacco product is subsequently punched out in pieces for oral use, preferably essentially circular pieces. The pieces are further preferably in size for use in the mouth, most preferred under the upper lip of a human being. If the pieces are circular they may preferably have a diameter of approximately 7 mm.

[0044] According to a preferred embodiment of the second aspect of the present invention the out-punched tobacco product is put on a carrier, preferably a strip of cloth, most preferred a cloth comprising heat-sealable non-woven, and optionally subsequently the cloth is sealed, preferably using heat.

[0045] According to a preferred embodiment of the second aspect of the present invention a further carrier, preferably a strip of cloth, most preferred a cloth comprising heat-sealable non-woven, is added on the other opposite side of the out-punched tobacco product, thus forming a sandwich with the tobacco product in the middle, and optionally subsequently the two carriers are sealed together, preferably using heat. The sealing may create a quadratic seal around each tobacco product (composition). The pieces (i.e. the tobacco product) with a diameter of approximately 7 mm, may be put between two strips of heat-sealable non-woven with a width of approximately 12 mm and sealed.

[0046] According to a preferred embodiment of the second aspect of the present invention a tobacco product obtainable by a method according to the second aspect is provided.

[0047] According to a preferred embodiment of the first and second aspect of the invention a container comprising one or more tobacco products, wherein preferably said container is a can with a lid, is provided.

[0048] According to a preferred embodiment of the first and second aspect of the invention i.e. one or more tobacco products are presented in the form of a spool, coil or reel.

[0049] Generally described the present invention provides according to the first aspect of the invention a tobacco product stabilized with hydrophobic plasticizers and constructed of more than one layer. The layers function to increase the nicotine yield or keep the nicotine yield high, hold the construction and improve the appearance. The present invention is constructed to function without chewing. The construction (the tobacco composition) will essentially be destroyed and the product will break up in pieces if it is chewed. The preferred use is under the upper lip of a human being. The product is essentially not soluble, just nicotine and taste are extracted from the invention when used in the mouth. In a non-chewing product nicotine release depends on the amount of nicotine and on the size of the surface exposed to saliva. In the present invention steps are taken to expand the surface. The product (the tobacco composition according to the first aspect) is made of thin layers loosely kept together, permitting saliva to wet the layers from between. The layers may preferably contain little plasticizers to promote some cracking, allowing salivia to penetrate the structure. To improve the appearance, “the stay in place performance” or the initial taste the exterior layers may contain other mixture, components or material compared to the inner ones. For example less tobacco, which makes it easier to colour. Stay in place improvement may be coating, “pattern” as set out above or a non-woven outer layer.

[0050] Preferred features of each aspect of the invention are as for each of the other aspects mutatis mutandis. The prior art documents mentioned herein are incorporated to the fullest extent permitted by law. The invention is further described in the following examples, which do not limit the scope of the invention in any way. Embodiments of the present invention are described in more detail with the aid of examples of embodiments, the only purpose of which is to illustrate the invention and are in no way intended to limit its extent.

EXAMPLES Example 1

[0051] This is a product for use under the upper lip. It can be made in strips to let the consumer decide the size or in portion pieces with different shapes. 25% titanium dioxide 30% tobacco powder

[0052] To form the invention all dry ingredients were first mixed. If the addition of sweeteners, pH adjusting agents, colours, flavours and others were large it was necessary to reduce the amount of titanium oxide or tobacco powder to keep the plastic properties. 11% glycerol 4% water

[0053] All wet components were stirred in. 25% chewing gum base (Smily 2 toco Pellets from Gum Base Company S.p.A., Italy)

[0054] The gum base was heated to about 70° C. before it was added. This mixture should be mixed to a smooth dough. Depending on the size of the batch, it might be necessary to heat the mixture. The dough was processed in a pasta machine (Atlas, manufactured by Marcato); rolled, sprinkled with cornstarch and folded. This was repeated for at least 30 times, to a thinner and thinner plate. The end thickness should be about 1 mm. This plate was the load layer. A backbone with a thickness less than 0,5 mm was made of gum base in a pasta machine. A backbone layer was put between two load layers and was rolled in the pasta machine to a product plate with a thickness of about 2 mm.

[0055] The pressure is critical by the use of the pasta machine—if it is to high it will damage or destroy the layers.

[0056] The product plate can be coated or patterned before the product is cut or punched out from it.

Example 2

[0057] This is punched pieces of the invention in a spool of non-woven. The product is easy to keep in place, it lets the customer decide dose and it has a clean look. 53% tobacco powder

[0058] To form the invention all dry ingredients were first mixed. If the addition of sweeteners, pH adjusting agents, colours, flavours and others are large it may be necessary to reduce the amount of tobacco powder to keep the plastic properties. 16% glycerol 9% water

[0059] All wet components were stirred in. 16% chewing gum base

[0060] The gum base was heated to about 70° C. before it is added. This mixture should be mixed to a smooth dough. The dough was processed in a pasta machine to make a thin plate. This dough is hard to get through the pasta machine, but no layers are needed. A plate with a thickness of 12-15 mm is sufficiently. This is the load layer. The exterior layers (cosmetic layers) were made according to the procedure in Example 1, but when a smooth dough was reached no layers were built up instead the dough was rolled to a very thin plate less then 0,5 mm thick. The load layer was put between two exterior layers and was rolled in the pasta machine to a product plate with a thickness of about 2 mm.

[0061] The product plate can be coated before the product is punched out in circular pieces about 7 mm in diameter. The pieces were put between two strips of heat-sealable non-woven with a width of 12 mm and sealed.

[0062] Various embodiments of the present invention have been described above but a person skilled in the art realizes further minor alterations, which would fall into the scope of the present invention. The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. For example, any of the above-noted methods and products can be combined with other known methods and products. Other aspects, advantages and modifications within the scope of the invention will be apparent to those skilled in the art to which the invention pertains. 

1. A tobacco composition comprising a multi-layer structure wherein the composition comprises at least one load layer and a construction layer.
 2. A tobacco composition according to claim 1 wherein the construction layer is either a backbone layer or a cosmetic layer.
 3. A tobacco composition according to claim 1 wherein the composition comprises at least two load layers with an intermediate construction layer, preferably a backbone layer.
 4. A tobacco composition according to claim 1 wherein the composition comprises at least two construction layers, preferably cosmetic layers, with an intermediate load layer.
 5. A tobacco composition according to claim 1 wherein the load layers comprise a load layer composition.
 6. A tobacco composition according to claim 5 wherein the load layer composition comprises tobacco powder, filler, a plasticizer, a solvent and a gum base.
 7. A tobacco composition according to claim 6 wherein the load layer composition comprises tobacco powder, titanium dioxide, glycerol, water and chewing gum-base.
 8. A tobacco composition according to claim 2 wherein the backbone layer comprises a construction layer composition or a solid fiber material.
 9. A tobacco composition according to claim 2 wherein the cosmetic layer comprises a construction layer composition or plastic or paper material or a combination thereof.
 10. A tobacco composition according to claim 2 wherein the construction layer composition comprises a gum base, and optionally tobacco powder, a plasticizer and a solvent.
 11. A tobacco composition according to claim 8 wherein the construction layer composition comprises a chewing gum base, and optionally tobacco powder, glycerol and water.
 12. A tobacco composition according to any one of the preceding claims comprising additionally a lipophilic softener.
 13. A tobacco composition according to any one of the preceding claims contained in cloth, wherein said cloth preferably comprises heat-sealable non-woven.
 14. A method for manufacturing a tobacco composition according to claim 1 comprising the following step: pressing at least one load layer with a construction layer in a press apparatus.
 15. A method for manufacturing a tobacco composition according to claim 3 comprising the following step: pressing at least two load layers, comprising a load layer composition, with an intermediate construction layer in the form of a backbone layer, comprising a construction layer composition, in a press apparatus.
 16. A method for manufacturing a tobacco composition according to claim 4 comprising the following step: pressing at least two construction layers in the form of at least two cosmetic layers, each comprising a construction layer composition, with an intermediate load layer, comprising a load layer composition, in a press apparatus.
 17. Method according to any one of claims 14 to 16 wherein the load layer composition has been manufactured using a method comprising the following steps: a) mixing tobacco powder, filler, plasticizer, and the solvent, b) heating the mixture; and c) adding a gum base.
 18. Method according to any one of claims 15 to 16 wherein the construction layer composition has been manufactured using a method comprising the following steps: a) heating gum base to a suitable consistency mixture; and optionally b) adding the gum base to a mixed solution comprising tobacco powder, a plasticizer and a solvent
 19. Method according to any one of claims 14 to 16 wherein one or more sweeteners, pH adjusting agents, colours or flavours are added.
 20. Method according to any one of claims 14 to 16 wherein the load layers are pressed repeatedly after folding, preferably more than 30 times, before the backbone layer is added to the load layers to form the multi-layered tobacco product.
 21. Method according to any one of claims 14 to 16 wherein a lubricant is distributed on the load layers before each folding, preferably the load layers are sprinkled with cornstarch before each folding.
 22. Method according to any one of claims 14-21 wherein the tobacco composition is coated with a coating layer or is patterned.
 23. Method according to any one of claims 14-21 wherein the tobacco composition subsequently is punched out in pieces for oral use, preferably essentially circular pieces.
 24. Method according to claim 23 wherein the out-punched tobacco composition is put on a carrier, preferably a strip of cloth, most preferred a cloth comprising heat-sealable non-woven, and optionally subsequently the cloth is sealed, preferably using heat.
 25. Method according to claim 24 wherein a further carrier, preferably a strip of cloth, most preferred a cloth comprising heat-sealable non-woven, is added on the other opposite side of the out-punched tobacco composition, and optionally subsequently the carriers are sealed together, preferably using heat.
 26. A tobacco composition obtainable by a method according to any one of claims 14-23.
 27. A container comprising one or more tobacco compositions according to any one of the claims 1 to 14 and 26, wherein preferably said container is a can with a lid.
 28. A tobacco composition according to any one of the claims 1-14 and 26 presented in the form of a spool, coil or reel. 